Cycling footwear structure with a composite sole and a method to realise such structure

ABSTRACT

Cycling footwear structure including a composite sole formed by at least one base sole and by at least one substantially annular shaped stiffening element, equipped with a front part, and with a back part and that extends progressively upwards until it wraps around at least one portion of the heel of a user and a method for making it.

TECHNICAL FIELD OF THE INVENTION

The present invention concerns a cycling footwear structure equipped with a composite sole and a method for making such a structure.

STATE OF THE ART

The development of technology in the field of sport footwear in general often comes up against the need, of production companies, to contain the production costs whilst still keeping a high quality product.

In particular, there is often the problem of having to abandon certain innovative technical solutions for producing high level products, in terms of performance and comfort, due to the high cost of procuring single moulds and/or moulds that can be taken apart which make it possible to obtain certain desired shapes and/or undercuts.

It is also important to be able to base the production of a product on a small number of production steps, so as to contain the time and costs related to the production.

SUMMARY OF THE INVENTION

One purpose of the invention is to improve the state of the art.

Another purpose of the invention is to make a cycling footwear structure that is equipped with a composite sole having high stiffness and resilience so as to increase the power generated by the athlete or by the user, and that is transmitted to the pedal through the footwear itself, and so as to increase the safety of the product.

According to one aspect of the present invention, these purposes are achieved with a cycling footwear structure as specified in the present disclosure.

A further purpose of the present invention is to provide a method for making a cycling footwear structure which makes it possible to contain the costs for the production equipment.

A further purpose of the present invention is to provide a method for making a footwear structure that is equipped with a composite sole with high stiffness so as to increase the power generated by the athlete or by the user and that is transmitted to the pedal through the footwear itself, and so as to increase the safety of the product.

According to one aspect of the present invention a method is foreseen for making a cycling footwear structure as specified in the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

Further characteristics and advantages of the invention shall become clearer from the detailed description of a cycling footwear structure, illustrated as an indication, and not for limiting purposes, in the attached drawings, in which:

FIG. 1 is a perspective top view of the composite sole of the cycling footwear structure according to the invention;

FIG. 2 is a bottom view of the composite sole according to FIG. 1;

FIG. 3 is a side view of the composite sole according to FIGS. 1 and 2,

FIG. 4 is a bottom view of the composite sole according to the previous figures;

FIG. 5 is a view from the section A′ of the composite sole according to the previous figures taken along the axis A-A of FIG. 4;

FIG. 6 is a view from the section B′ of the composite sole according to the previous figures taken along the axis B-B of FIG. 4;

FIG. 7 is a view from the section C′ of the composite sole according to the previous figures taken along the axis C-C of FIG. 4;

FIG. 8 is a view from the section D′ of the composite sole according to the previous figures taken along the axis D-D of FIG. 4.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

With reference to the figures, 1 indicates a composite sole of a cycling footwear structure (not illustrated) according to the present invention.

Said composite sole 1 is made up of at least two parts: the first part that comprises a base sole 2 and the second part made up of at least one stiffening element 3.

The stiffening element 3 is substantially annular-shaped with a variable section passing from its front part 5 to its back part 6.

The base sole 2, as visible in FIG. 2, has, substantially along at least part of its perimeter, a recess 4, in which the front part 5 of the stiffening element 3 is positioned.

As visible in FIGS. 4-8, the stiffening element 3 has, in its front part 5, a section A′, taken along the axis A-A of FIG. 4. Such a section A′ is substantially two-dimensional, with the two dimensions being substantially equal to one another.

Section A′ can also have other configurations and/or geometries that are different from the two-dimensional one, without for this reason departing from the scope of protection of the present invention. Such a section A′ substantially corresponds to the shape of the recess 4, inside which the front part 5 of the stiffening element 3 is positioned.

Sliding towards the back part 6 of the stiffening element 3, its section undergoes a predetermined variation of thickness and of geometry progressively becoming one-dimensional, with a main dimension, with a lower thickness with respect to section A′ and with a substantially membrane-type configuration. Concerning this, in FIGS. 6, 7 and 8 the sections B′, C′ and D′ are shown obtained by sectioning the stiffening element 3 respectively along the axes B-B, C-C and D-D of FIG. 4. In the front area 5 of the stiffening element 3, the dimensions of the section A′ are substantially of the same order of magnitude whereas in the back part 6 of the stiffening element 3, one dimension of section D′ has an order of magnitude that is greater with respect to the other dimension.

In addition to its front part 5, at least also part of the central area of the stiffening element 3, which goes from its front part 5 until about half way, substantially at the axis C-C, is positioned inside the recess 4 of the base sole 2. The back part 6 of the stiffening element 3 come out from the recess 4 starting from about half way, substantially at the axis C-C, and extends upwards, until it wraps around at least one portion of the heel of a user, that is to say at least the upper part of the heel and/or its central part which has a perimetral extension which is slightly smaller with respect to the maximum perimetral extension of the heel itself.

In such a way, the back part 6 of the stiffening element 3 blocks the heel and, thanks to the variation in its section and of the composition of the material with which it is made, the stiffening element 3 makes a reinforcing element that helps, while pedalling, to reduce the power dissipated due to the elastic deformation of the composite sole 1 and to increase the comfort, thanks to an optimal distribution of the pressure at the interface of the heel with the back part 6, with the variation of the anatomical configuration of the heels of the different users.

In such a way it is possible to join the functions of containment of the heel and of stiffening of the composite sole 1, so as to improve and increase the power generated by the user and transmitted to the pedal through the footwear itself.

The stiffening element 3 further comprises at least one insert 7, positioned in the back part 6. The back part 6 of the stiffening element 3 and the at least one insert 7 wrap around at least one portion of the heel of a user, that is to say, at least its upper and/or central part. Such components, in any case, can wrap around the heel of the user either completely or only partially, without for this reason departing from the scope of protection of the present invention.

The insert 7 is made up of a flexible material which has stiffness characteristics that are different from the material forming the stiffening element 3 and from the material forming the base sole 2.

This insert 7 determines the comfort of the fitting of the user's foot, held by the back part 6 of the stiffening element 3 inside the footwear structure equipped with such a composite sole 1, and blocks the foot itself.

The composite sole 1, comprising components, such as the base sole 2, the at least one stiffening element 3 and the at least one insert 7, with different geometrical and physical characteristics, makes it possible to easily produce a wide array of products having different comfort and stiffness characteristics which better adapt to the needs of the users. It is indeed possible to make composite soles 1, possibly equipped with inserts 7 that are integrated in the stiffening element 3, with different and optimised characteristics according to the needs of a user, selecting different materials for the various components and making such components with personalised and/or variable thickness.

The insert 7 is made up of a material that is substantially rigid comprising a plastic material reinforced with fibres (Fibre Reinforced Plastic, FRP), like for example a polyamide and/or polyurethane and/or, in general, thermoplastic material reinforced with carbon fibres and/or glass fibres and/or aramid fibres and/or the same fibres bonded to an epoxy and/or, in general, thermosetting matrix and/or, more generally, a tough composite material with high modulus elasticity.

In such a way, the insert 7, and in general all the back part 6, does not have fragility problems.

The stiffening element 3 is made up of a material with a different stiffness with respect to the material of the insert 7 and it can possibly comprise a base plastic material of a thermoplastic or thermosetting type that, in turn, can possibly comprise fibres, such as kevlar fibres and/or polyester and/or rubber and/or carbon fibres and/or glass fibres.

In an alternative embodiment, the insert 7 makes it possible to optimise the comfort of the footwear by making a variable stiffness. In particular such a stiffness decreases starting from the area of the insert 7 in contact with the base sole 2 until it reaches the upper area of the insert 7.

Such a variable stiffness is obtained through a reduction of the thickness of the stiffening element 3 and/or of the mechanical characteristics of the insert 7.

The characteristics of the insert 7 listed above make it possible to avoid the drawbacks of the prior art. Conventional heel seat linings, indeed, are integrated with the sole and are made with the same materials as the latter. However, the sole is made with materials with high stiffness so as to transmit the power developed by the cyclist while pedalling and this high stiffness makes conventional heel seat linings fragile, causing them to break easily with the consequent risk of the user getting injured.

The base sole 2 comprises an epoxy resin with which carbon fibres are combined.

The fibres of the aforementioned materials have a preferred flow, possibly not rigidly structured like warp and weft.

The present invention also concerns a method for making a footwear structure equipped with a composite sole 1.

In particular, said method allows the manufacturer to lower the costs of procuring the moulds and to obtain footwear which can adapt to heels of different shapes and sizes.

Moreover, it is possible to reduce the investments, in moulds, necessary for making a wide array of soles: with the present method it is indeed possible, to modify even only one of the production moulds to obtain composite soles with different characteristics and/or it is possible to simplify the construction of the production moulds by making shapes of soles or components thereof which would otherwise require very expensive or unfeasible moulds.

The method for making a footwear structure equipped with a composite sole 1 comprises the following steps: providing a mould, possibly equipped with a suitable seat for an insert 7, manually or automatically positioning an insert 7 inside the mould, possibly in its special seat; the method also comprises the steps of providing a mould, manually or automatically inserting the material making up the stiffening element 3, forming the stiffening element 3 by compression or by injection, respectively.

In such a way at least one stiffening insert 3 and at least one insert 7 are obtained, both made from the aforementioned materials, selected so as to be compatible. In one alternative embodiment, the materials with which the at least one insert 7 and the at least one stiffening element 3 are made, are not compatible. There is therefore a step in which such materials are treated with known compatibilizing agents.

The method according to the invention also comprises the following steps: providing a mould, arranging the stiffening element 3, possibly equipped with at least one insert 7; the method also comprises the steps of inserting the material that makes up the base sole 2, forming the base sole 2 by compression and by heat, possibly equipped with at least one recess 4; the method also comprises the step of substantially positioning the front part 5 of the stiffening element 3 in the recess 4.

In such a way at least one stiffening insert 3, at least one insert 7 and at least one base sole 2 are obtained made in the aforementioned materials, selected so as to be compatible. In an alternative embodiment, the materials with which the at least one insert 7, the at least one stiffening element 3 and the base sole 2 are made, are not compatible. There is thus a step of treating such materials with known types of compatibilizing agents.

After the composite sole 1 has been made according to the invention, made with the aforementioned method, there is a step of trimming and finishing the sole, which is carried out mechanically.

The aforementioned steps can be made in the same order as described above or in a different order at different times; moreover, the steps described can be made in any order. For example it is possible to make the at least one stiffening element 3, the at least one base sole 2 and the at least one insert 7 separately; it is possible to make in the same mould and/or couple the at least one stiffening element 3 and the at least one insert 7, during or after the step of making the stiffening element 3, and couple such components to the base sole 2; it is alternatively possible to couple and/or make in the same mould the at least one stiffening element 3 and the at least one base sole 2, during or after the step for making the stiffening element 3 and/or the base sole 2 and then couple such elements with the at least one insert 7, etcetera.

In one alternative embodiment, the elements that form the composite sole 1 according to the present invention can be made in a single mould, simultaneously or in successive steps, or by inserting a subsequent mould inside one that has already been arranged.

The methods for coupling the aforementioned elements can be manual and/or managed by special machinery and/or can occur by co-moulding and/or by gluing of at least two of the elements together. In order to make the insert 7, from composite material with thermoplastic or thermosetting matrix, a starting material is provided, made up of a dry fabric made from the aforementioned carbon and/or glass and/or aramid fibres.

In the case in which the insert 7 is of the thermoplastic matrix type, two layers of thermoplastic resin are provided and the coupling of such a dry fabric based on fibres is carried out with the two layers of thermoplastic resin arranged above and below the dry fabric itself, respectively.

Such a coupling operation is carried out through heat and pressure which, together, obtain the impregnation of the dry fabric based on fibres described above, by the thermoplastic resin.

After such an impregnation step has been carried out, a sheet or strip of impregnated fabric is obtained from which it is possible to make, through cutting or blanking, at least one insert 7. The insert 7 thus obtained has a flat shape and can possibly undergo a further thermoforming step, made in a special mould, which makes the thermoformed insert 7 substantially U-shaped, or at least able to match at least one portion of a heel of a user.

In the case in which the insert 7 is of the thermosetting matrix type, a thermosetting resin is provided without cross-linking and such a dry fabric based on fibres is coupled with the thermosetting resin.

Such a coupling operation determines the preimpregnation step of the dry fabric based on fibres.

After such an impregnation step has been carried out, a sheet or strip of pre-impregnated fabric is obtained from which it is possible to make, through cutting or blanking, at least one insert 7. The insert 7 thus obtained is positioned in a mould and is formed by compression with pressure and heat. In such a way, an insert 7 is obtained that is substantially U-shaped, or at least matches at least one portion of a heel of a user.

Also in this case, the aforementioned steps can be carried out in the same order as described above or in different order and at different times; moreover, the steps described can be made in any order.

The present invention thus conceived can undergo numerous modifications and variants all covered by the scope of protection of the claims. 

1. Cycling footwear structure comprising a composite sole comprising at least one base sole, wherein it comprises at least one substantially annular shaped stiffening element, equipped with a front part and with a back part and that extends progressively upwards until it wraps around at least a portion of the heel of a user.
 2. Cycling footwear structure according to claim 1, wherein said base sole is equipped with at least one recess arranged substantially along at least part of the perimeter of said base sole, in which said at least one stiffening element is at least partially positioned.
 3. Cycling footwear structure according to claim 1, wherein said at least one stiffening element comprises at least one insert.
 4. Cycling footwear structure according to claim 1, wherein said at least one stiffening element extends progressively upwards until it wraps around at least the upper part and/or the middle part of the heel of a user.
 5. Cycling footwear structure according to claim 1, wherein said at least one stiffening element has sections (A′, B′, C′ and D′) of thickness and geometry that can be varied in a predetermined manner.
 6. Cycling footwear structure according to claim 5, wherein said section (A′) is substantially two-dimensional, with the two dimensions being substantially equal to one another, and matches said at least one recess of said base sole.
 7. Cycling footwear structure according to claim 5, wherein said section (D′) is substantially one-dimensional, with a main dimension, of lower thickness than said section (A′) and with a substantially membrane-type configuration.
 8. Cycling footwear structure according to claim 5, wherein said sections (B′, C′ and D′), positioned progressively towards said back part of the at least one stiffening element, have a substantially elongated configuration with lower thickness than said section (A′).
 9. Cycling footwear structure according to any claim 3, wherein said at least one insert is positioned in said back part of said at least one stiffening element.
 10. Cycling footwear structure according to claim 3, wherein said at least one insert comprises a flexible material that has different stiffness characteristics from the material that makes up said at least one stiffening element and said base sole.
 11. Cycling footwear structure according to claim 3, wherein said at least one insert comprises a substantially rigid material comprising a plastic material reinforced with fibres (Fiber Reinforced Plastic, FRP), including a polyamide and/or polyurethane and/or, in general, thermoplastic material reinforced with carbon fibres and/or glass fibres and/or aramid fibres and/or the same fibres bonded to an epoxy and/or, in general, thermosetting matrix and/or, more generally, a tough composite material with high modulus of elasticity.
 12. Cycling footwear structure according to claim 1, wherein said at least one stiffening element comprises a base plastic material of a thermoplastic or thermosetting type that can optionally comprise fibres, such as kevlar fibres and/or polyester and/or rubber and/or carbon fibres and/or glass fibres.
 13. Cycling footwear structure according to claim 1, wherein said base sole comprises an epoxy resin with which carbon fibres are combined.
 14. Method for making a cycling footwear structure comprising a composite sole comprising at least one base sole and at least one substantially annular shaped stiffening element, equipped with a front part and with a back part, wherein it comprises the following steps: providing a mould, manually or automatically inserting the material making up said at least one stiffening element, forming said at least one stiffening element by compression or by injection.
 15. Method for making a cycling footwear structure according to claim 14, comprising the following steps: providing a mould, manually or automatically inserting the material making up said base sole, forming said base sole by compression, optionally equipped with at least one recess arranged substantially along at least part of the perimeter of said base sole.
 16. Method for making a cycling footwear structure according to claim 14, comprising the following steps: providing a mould, optionally equipped with a special seat, manually or automatically positioning at least one insert, coupling said at least one stiffening element with said at least one insert positioned in the back part of said at least one stiffening element.
 17. Method for making a cycling footwear structure according to claim 14, comprising a step of treating said at least one stiffening element and/or said at least one insert and/or said at least one base sole with compatibilizing agents.
 18. Method for making a cycling footwear structure according to claim 14, wherein said at least one stiffening element, said at least one base sole and said at least one insert are obtained in a single mould.
 19. Method for making a cycling footwear structure according to claim 14, wherein said at least one stiffening element, said at least one base sole and said at least one insert are coupled manually and/or through special machinery and/or by co-moulding and/or by gluing of at least two of said elements together.
 20. Method for making a cycling footwear structure according to claim 14, wherein said at least one stiffening element, said at least one base sole and said at least one insert have a predetermined stiffness/flexibility that can undergo variations both by modifying the composition of the various materials and by varying their thickness and geometry.
 21. Method for making a cycling footwear structure according to claim 14, wherein said method comprises the step of trimming and finishing the composite sole carried out mechanically.
 22. Method for making a cycling footwear structure according to claim 14, wherein said at least one insert is made according to the following steps: providing a starting material consisting of a dry fabric based on carbon and/or glass and/or aramid fibres, coupling said dry fabric based on fibres with a thermoplastic or thermosetting resin, obtaining a dry fabric based on fibres impregnated with said thermoplastic or thermosetting resin, obtaining said at least one insert by cutting or blanking.
 23. Method for making a cycling footwear structure according to claim 22, wherein said at least one insert is formed by compression or thermoforming and at least matches at least one portion of the heel of a user. 